Club Car 2008-2011 Maintenance And Service Manual page 194

7
POWERDRIVE 3 – MODEL 26580
Transformer
The PowerDrive 3 battery charger transformer has two sets of coils: a primary coil and a secondary coil
(Figure 7-10, Page 7-15).
Primary Coil
1. Disconnect AC cord (6) from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Carefully cut the heatshrink (7) that insulates the AC cord white wire (4) where it connects to the tan pri-
mary coil wire and disconnect the white wire (4) (Figure 7-22, Page 7-25).
4. Disconnect the black primary coil wire (5) from the relay (Figure 7-22, Page 7-25).
5. Place the continuity tester probes on the disconnected primary coil wires. The tester should indicate con-
tinuity. If tester does not indicate continuity, replace the transformer.
6. If the correct readings were obtained, install the AC cord and connect the transformer primary coil wires.
See AC Cord Installation on page 7-33.
Secondary Coil
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Remove the orange and purple transformer secondary coil wires (1 and 2) from each diode (Figure 7-9,
Page 7-11).
4. Place the continuity tester probes on the disconnected secondary coil wires. The tester should indicate
continuity between the orange and purple wires. If tester does not indicate continuity, replace the trans-
former.
Voltage Suppressor – Failed Closed
The voltage suppressor, which is incorporated into the relay board assembly, protects the onboard computer
by capturing very high, but very brief voltage spikes which occur due to the collapse of the electrical field in the
charger relay when the charger is disconnected from the vehicle.
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Using a multimeter set to the diode test function (
sense lead pin (short pin) of the DC plug. Place the red (+) probe on the positive (+) pin of the DC plug.
The multimeter should indicate 1.5 (±.3) volts. If a reading of <.5 volt, then the voltage suppressor has
shorted and the relay should be replaced. If the meter indicates an overload condition, then the voltage
suppressor has failed and the relay should be replaced. See following NOTE.
NOTE: All vehicles except Precedent: Repeated failure of sense lead fuses is a symptom of a voltage
supressor that has failed in a closed condition.
Precedent vehicles only: Failure of the onboard computer (prior to Version 3.0) due to a blown
internal sense lead fuse is a symptom of a voltage supressor that has failed in a closed condition.
The Version 3.0 and 4.0 onboard computers will quickly flash the battery warning light on the dash
to indicate a problem with the voltage supressor.
Page 7-26 2008-2011 Domestic Battery Charger Maintenance and Service Manual
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), place the black (–) probe of the multimeter on the
Test Procedures